Floor covering and process of making the same



Patented Nov. 17 i925,

Arr FFICE;

CALEB MARSHALL TAYLOR. 6F ELIZABETH, NEW JERSEY.

rnoon covnmns AND rnocnss or ivrsnme rein SAME.

K6 llrais'ing Application filed January 10,1922, Serial N01 528,297. hallowed September 1,1925

I i To all 'w/mwi it may concern:

Be it lmown that I, CALEB lilnusiunn TAY- Lou, u citizen of the l nited States. residing: n t Elizabeth. in the county t l nio'n and 1 State of New Jersey, have invented certain new and useful Improvements in Floor Coverings and Processes. of Melting the i tioiu it V f y -This invention relutes to floor roverings and to u process of making; the some. V The "floor covering provided is otthut I type known as felt base floor-coverings and particularly such inateriols in which on us- 1 phelt or bitumen impregnated base is used r and constitutes an improvement over such materials.

-The invention is also peculiarly adapted for use in combination with all floor cover- 2 ings in Whieheither-the Wear surface or the opposite face is formedof puint or other material containing l nseed Oil or other Oll, orany material subject to seponification 0r removableunder the action of soup and the 2 usual floor cleaning, materials.

i Bitumen impregnated felt busefloor covi erings may be recognized by the main dark body which is particularly evident when the .muterial is cut. The felt of such buses may be made from rugs, or from paper, or any cellulose material, or from uinixture oisuch materlals, thoroughly impregnated with asphsl-t or tar or some suitable bituminous material. 'When usedus a supporting base for floor covering it is the usual practice to coatthe bitumen impregnated buss with a layer off-paint end. often to apply various painted designs, all of which may be applied in any convenient manner. Also, a coat of.

4 paint is applied to the opposite or under surfece of theimpre'gnatecl base to'cover the ,"derk and unsightly bitumen impregnated- I In the manufacture of such bitumen imfi pregnated bases ithas been found that the wear'pamtend-the decorative point may be come discolored,;due in part to the next' 1nterior material of the bitumen of the bese.

Also in drying the'paint coats it is necessary 5 to dry at relativelylow temperatures and for at longer period) of time, often as long Sumo, of which the following is aspecificasaturant solution is us four orlive days. A higher temperature the paint zind also discolor the paint due to the release of materials from the base. Thus -a baking temperature of 175 F. orniore is rolled or stacked in luyersto prevent the adjacent painted surfaces from adhering. It is Well known that all such painted sur faces, and also that the'surfuce of the mateand more rapid drying would tend to liquet'y the bitumen and delay proper drying of between adjacent surfaces when the material.

i'iul known linoleum, is worn away by the use of soap and water because of the saponificution by such cleaning materials on the oils in the point and linoleum.

The present invention provides an impregnotedv felt base possessing the desirable cl'iurscteristic's of bitumen impregnated buses ofdurability, flexibility and softness, and is also -'"Waterproof and weatherproof.

Most important, the'inipregnuting material will not soil and may be subject to relatively high baking temperatureswithout discolor- The use of the base or this IYIWIXlIUI renders it unnecessary toing the paint thereon.

apply the coat otpaint to the under surface of the floor covering, renders it unnecessary to use the spacing paper, and evoids all danger of discoloration of the decorative or wear costs" of paint, 'and finally makes it possible to complete the. drying of, the point coats in'fa much shorter length of time than heretofore possible where bitumen impregnoted bases are used,

- .In producing the inipreg'neted felt boss of this invention, the -usual rolls offelt of the floor covering. 'typema' be used. A

repere ofv nitrocellulose an a solvent therefor.

of a, mixture.

Preferably e substantial quantity of a semidrying or drying, vegetable oil is added to the mixture as a softening muterieh'end it is desirable. to add a quantity of resin. -.Cu-

msron is an example of a suitable resin. To this cellulose mixture me be added a pig. ment color of any desi sl'mde a; feature not heretofore known in floor coverings. The mixtureis brought to the desired working tenu'ierature and the felt is saturated with it by being passed through tanks, or other suitable applying means, and finally it is passed through pressure rolls to press out all excess saturant solution. The felt is then dried at a suitable temperature, for instance, approximately 140 F. for 5 to 15 minutes, after which it may be used or coated as desired. In the claims, dried or dry means that the product is not sticky or tacky, and is in condition to be laid on a floor without danger of adhering to the tloor. It .is likewise so dry that it may properly receive paint coats.

Other cellulose esters than nitrocellulose, such as acetyl cellulose, may be used.

One satisfaewry mixture for the saturant solution may be made by using 10 parts by weight of nitrocotton, and parts of weight of a solvent mixture, which mixture may be composed of 35 per cent of acetone oil and 65 per cent of such a diluent solvent naphtha, or xylol, or toluol, or benzol. Any well known working formula may be used for combining such a mixture of drying or semi-drying vegetable oil with nitrocotton. To such a mixture 30 parts by weight of linseed oil or other semi-drying or drying vegetable oil can be added. Also, 5 parts by weight of a resin could be incorporated in the mixture The amount of coloring pigment may be varied as desired.

The resultant material may be used as the desirable tough, clean floor covering base having the above mentioned desirable qualities of a bitumen impregnated base and none of the recognized undesirable features. .\s a result of the treatment, the tensile strength. of the base is increased at least 23 per cent, and the material of the'lfelt is cemented together. it is thus possii'ile to use a relatively cheap grade of felt. 'lhis n'ocess toughcns the texture of the felt,

gives it a smooth surface. and better base for paint coats than the base provided by bitumen materials, and there is no tendency ,to bleed sticky tarry material as where bitumen felts are used, neither is it necessary to use a, sealing coat on this saturated 'l' lt before applying the printor decorative coat. it is a particularly necessary feature thatthc 't'elt be relatively smooth so that the resultant finish is smooth enough to receive evenly the usual printed de orative effects such as are ordinarily applied by block printing machines.

I claim .l. A floor covering comp ising a dry felt base of the lioor covering type impregnated throughout with a cellulose ester saturant which includes a drying oil.

lloor covering comprising a dry felt base of the floor covering type impregnated throughout; with a Intro-cellulose saturant which includes a drying oil.

3. A floor covering comprising a dry felt base of the lioor covering type impregnated throughoutwith a nitro-cellulose saturant combined with a resin and a drying oil.

at. .l\45llll()l covering comprising a dry felt base. of the floor covering type impregnated throughout with a saturant. of a mixture of intro-cellulose, a drying oil, and a coloring material.

5. A floor covering comprising a dry felt base of the floor. covering type impregnated throughout with a cellulose ester non-saponitiable material.

6. The process of making an impregnated felt base floor covering, which process comprises saturating a dry felt base of the 'floor covering type throughout with a saturant containing in solution 10 parts by weight of a cellulose ester, and 90 parts of a solvent therefor, and drying the base thus treated. 7. The recess of makn an impregnated l'elt base oor covering, which process comprises saturating a d felt base of the floor covering type throng out with a saturant containing in solution 10 parts by weight of a cellulose ester, 90parts of a solvent therefor, 30 parts of a drying vegetable oil, and drying-the base thus treated.

8. The rocess of making an impregnated t'elt baseoor covering, which process comprises saturating a dry felt base of the floor covering type throughout with a saturant containing in solution 10 parts by weight of a cellulose ester, 90 parts of a.solvent therefor, and 30 parts of a softening medium. and drying the base thus treated.

S). The process of making an impregnated 't'elt base floor covering, which process comprises saturating a dry felt base of the/floor covering type throughout with a saturant containing in solution 10 parts by weight of 1 1 itroeellnlosc and 90 parts of a sol vent therefor. and drying the base thus treated.

it). The process of making an imprcgnated felt vase floor covering, which process comprises saturating a dryfelt base of the tloor covering type throughout with a saturant containing in solution 1.0 parts by weight; of nitrocellulose, 90 parts of a solent therefor, and 30 parts of a drying vegetable oil, and drying the base thus treated.

11. A. floor covering con'iprising a dry felt base of the lioor covering type impregnated throughout with a saturant containing a. mixture. of nitrocclluiasc, a coloring material, and a drying vegetable oil.

12. A door covering comprising a dry felt lnise ot' the floor covering type impregnated throughout with a saturant containing a mixture of nitrocellulose, a covering mate rial, a drying vegetable oil. and a resin.

3. The process of making an impregnated tclt base floor covering which commmms a prises saturating an absorbent felt base of strength of felt base floor coverings which the finor covering type with a sub? m a comprises saturating an absorbent felt bage cvllulosu taste! mixed with $3 tinw. Eta @ily ufi' the floor covering type with a mixturepf 1 .C weight of drying vegetable oiL-nnd drying a celluiose ester and a drying vegetabfi-gili 5 the material thus treated at a tculpcrature 1n testinwny whereof I affix my signatiire.

' of approximately M0 F.

1%. The process of ingreasing the tensile CALEB MARSHALL 

